Part 1

1. Remove the engine. Service and Repair






2. Remove the bolts and the flexplate.






3. Remove the engine/transmission spacer plate.






4. Mount the engine on a suitable engine stand.






5. Remove the LH and the RH lifting brackets.






6. Remove the bolts and the RH engine mount.

7. NOTE: LH shown; RH similar.






Remove the drain plugs from the engine block. Allow the coolant to completely drain.

- Install the drain plugs when finished.






8. Rotate the accessory drive belt tensioner and remove the accessory drive belt.






9. Remove the bolt and the battery cables from the engine.






10. Disconnect the crankshaft position (CKP) sensor electrical connector.






11. Disconnect the A/C compressor electrical connector.






12. Disconnect the oil pressure sensor and the power steering pressure (PSP) switch electrical connectors, and detach the wiring harness anchor.






13. Disconnect the exhaust gas recirculation (EGR) tube from the exhaust manifold.






14. Disconnect the two differential pressure feedback EGR hoses.






15. Disconnect the eight ignition coil electrical connectors.






16. Disconnect the eight fuel injector electrical connectors.






17. Remove the bolts and the EGR tube heat shield.






18. Remove the crankcase ventilation tube.







19. Disconnect the EGR vacuum regulator solenoid electrical connector.

20. Disconnect the fuel charging wiring electrical connector from the differential pressure feedback EGR.






21. Remove the generator mounting bracket.
- Remove the bolts.
- Remove the bracket.






22. Disconnect the idle air control (IAC) and the throttle position (TP) sensor electrical connectors.






23. Disconnect the generator electrical connector






24. Disconnect and detach the cylinder head temperature (CHT) sensor.






25. Remove the power steering reservoir and bracket as an assembly.
- Disconnect the supply hose.
- Remove the three bolts and the reservoir.






26. Remove the generator wiring harness anchor from the LH front stud.






27. Disconnect the ground wire from the RH rear stud.






28. Disconnect the engine coolant temperature (ECT) sensor electrical connector.






29. Disconnect the camshaft position (CMP) sensor electrical connector.






30. Disconnect the radio ignition interference capacitor and remove the engine control sensor wiring.






31. Disconnect the fuel charging wiring from the crash bracket and the wiring support bracket and remove the harness from the engine assembly.






32. Disconnect the EGR tube nut from the EGR valve.






33. Remove the generator.
- Remove the bolts.
- Remove the generator.






34. Remove the bolt and nut; remove the wiring bracket.






35. Remove the throttle return spring.






36. Remove the four bolts and the throttle body.






37. Remove the bolt and the stud. Remove the crash bracket.






38. Remove the eight bolts and the eight ignition coils.

Natural Gas Engines







39. Disconnect the fuel charging wiring electrical connector from the fuel pressure sensor.






40. Disconnect the fuel charging wiring electrical connector from the fuel temperature sensor.






41. Separate the isolation valve wiring lead from the generator support bracket and disconnect.